OWNER S MANUAL XJR1300 XJR1300SP 5EA E2

Transcription

1 OWNER S MANUAL XJR1300 XJR1300SP 5EA E2

2 EAU00001 INTRODUCTION Welcome to the Yamaha world of motorcycling! As the owner of a XJR1300/XJR1300SP, you are benefiting from Yamaha s vast experience in and newest technology for the design and the manufacture of highquality products, which have earned Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all your XJR1300/ XJR1300SP s advantages. The owner s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury. In addition, the many tips given in this manual will help to keep your motorcycle in the best possible condition. If you have any further questions, do not hesitate to contact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first!

3 IMPORTANT MANUAL INFORMATION EAU00005 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING CAUTION: NOTE: Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer. NOTE: This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.

4 IMPORTANT MANUAL INFORMATION EW WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

5 IMPORTANT MANUAL INFORMATION EAU00008 XJR1300/XJR1300SP OWNER S MANUAL 1999 by Yamaha Motor Co., Ltd. 1st Edition, July 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

6 EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 1 2 DESCRIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE-OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX

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8 GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY

9 1-GIVE SAFETY THE RIGHT OF WAY EAU Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving your motorcycle s value and operating condition. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle riders - more than car drivers - must always be at their mental and physical best. Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks. Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should not encourage carelessness. Though full-coverage helmets and suits, in particular, create an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides safely, predictably and defensively - avoiding all dangers, including those caused by others. Enjoy your ride! Give safety the right of way 1-1

10 DESCRIPTION Left view Right view Controls/Instruments

11 2-DESCRIPTION EAU00026 Left view 2 1. Clutch fluid reservoir (page 6-18) 2. Fuel cock (page 3-10) 3. Rear shock absorber spring preload adjusting ring (page 3-13) 4. Luggage strap holders (page 3-15) 5. Helmet holder/seat lock (page 3-12 / page 3-11) 6. Shift pedal (page 3-7) 7. Engine oil filter element (page 6-8) 2-1

12 DESCRIPTION Right view 2 8. Tail/brake light (page 6-27) 9. Luggage strap holders (page 3-15) 10. Tool kit (page 6-1) 11. Rear brake fluid reservoir (page 6-18) 12. Fuses (page 6-25) 13. Air filter (page 6-10) 14. Fuel tank (page 3-9) 15. Front brake fluid reservoir (page 6-18) 16. Headlight (page 6-25) 17. Rear brake pedal (page 3-8) 2-2

13 DESCRIPTION Controls/Instruments 2 1. Clutch lever (page 3-7) 2. Left handlebar switches (page 3-5) 3. Starter (choke) (page 3-11) 4. Speedometer (page 3-4) 5. Fuel gauge (page 3-5) 6. Tachometer (page 3-4) 7. Right handlebar switches (page 3-6) 8. Front brake lever (page 3-8) 9. Throttle grip (page 6-12) 10. Main switch/steering lock (page 3-1) 11. Front fork spring preload adjusting bolt (page 3-13) 2-3

14 INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock Indicator lights Oil level indicator circuit check Speedometer Tachometer Antitheft alarm (optional) Fuel gauge Handlebar switches Clutch lever Shift pedal Front brake lever Rear brake pedal Fuel tank cap Fuel Fuel cock Starter (choke) Seat Helmet holder Storage compartment Front fork adjustment Rear shock absorber adjustment Luggage strap holders Sidestand Sidestand/clutch switch operation check

15 3-INSTRUMENT AND CONTROL FUNCTIONS EAU EAU00029* Main switch/steering lock The main switch controls the ignition and lighting systems. Its operation is described below. EAU00036 ON Electrical circuits are switched on. The engine can be started. The key cannot be removed in this position. EAU00038 OFF All electrical circuits are switched off. The key can be removed in this position. EAU00040 LOCK The steering is locked in this position and all electrical circuits are switched off. The key can be removed in this position. To lock the steering, turn the handlebars all the way to the left. While pushing the key into the main switch, turn it from OFF to LOCK and remove it. To release the lock, turn the key to OFF while pushing. 1. Push 2. Turn EW WARNING Never turn the key to OFF or LOCK when the motorcycle is moving. The electrical circuits will be switched off which may result in loss of control or an accident. Be sure the motorcycle is stopped before turning the key to OFF or LOCK. 3-1

16 INSTRUMENT AND CONTROL FUNCTIONS EAU01590 (Parking) The steering is locked in this position, and the taillight and auxiliary light come on but all other circuits are off. The key can be removed in this position. To use the parking position, first lock the steering, then turn the key to. Do not use this position for an extended length of time as the battery may discharge. 1. Left turn indicator light 2. High beam indicator light 3. Neutral indicator light 4. Right turn indicator light 5. Oil level indicator light Indicator lights EAU00056 EAU00058 Turn indicator lights / The corresponding indicator flashes when the turn switch is moved to the left or right. EAU00061 Neutral indicator light This indicator comes on when the transmission is in neutral. EAU01313 Oil level indicator light This indicator comes on when the oil level is low. This light circuit can be checked by the procedure on page 3-3. EC CAUTION: Do not run the motorcycle until you know it has sufficient engine oil. NOTE: Even if the oil is filled to the specified level, the indicator light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is normal. 3 EAU00063 High beam indicator light This indicator comes on when the headlight high beam is used. 3-2

17 INSTRUMENT AND CONTROL FUNCTIONS Oil level indicator circuit check EAU00073 CB-52E Turn the main switch to ON. Turn the engine stop switch to. Wait a few seconds (see NOTE). NOTE: When the main switch is turned on, the oil level indicator light will come on for a few seconds and then go off. If the indicator light does not come on, ask a Yamaha dealer to inspect the electrical circuit. 3 Oil level indicator light goes off. Oil level indicator light remains on. Put the transmission in neutral or apply the clutch lever, then push the start switch. Check engine oil level. Oil level indicator light comes on. Oil level indicator light still does not come on. Oil level is OK. Oil level is low. Engine oil level and electrical circuit are OK. Go ahead with riding. Ask a Yamaha dealer to inspect electrical circuit. Supply engine oil. 3-3

18 INSTRUMENT AND CONTROL FUNCTIONS EAU00109 Antitheft alarm (optional) An antitheft alarm can be equipped to this motorcycle. Consult your Yamaha dealer to obtain and install the alarm Reset knob 2. Tripmeter 3. Odometer 4. Speedometer EAU00097 Speedometer The speedometer shows riding speed. This speedometer is equipped with an odometer and trip odometer. The trip odometer can be reset to 0 with the reset knob. Use the odometer together with the fuel gauge to estimate how far you can ride on a tank of fuel. This information will enable you to plan fuel stops in the future. 1. Tachometer 2. Red zone EAU00101 Tachometer This model is equipped with an electric tachometer so the rider can monitor the engine speed and keep it within the ideal power range. CAUTION: Do not operate in the red zone. Red zone: 9,500 r/min and above EC

19 3 INSTRUMENT AND CONTROL FUNCTIONS 1. Fuel gauge 1. Pass switch PASS 2. Dimmer switch EAU Turn signal switch 4. Horn switch Fuel gauge This model is equipped with an electric fuel gauge so the rider can monitor the fuel level in the fuel tank. When the needle indicates E (Empty), about 4.5 L remain in the fuel tank. Handlebar switches EAU00118 EAU00120 Pass switch PASS Press the switch to operate the passing light. EAU00127 Turn signal switch To signal a right-hand turn, push the switch to. To signal a left-hand turn, push the switch to. Once the switch is released it will return to the center position. To cancel the signal, push the switch in after it has returned to the center position. Horn switch Press the switch to sound the horn. EAU00129 EAU00121 Dimmer switch Turn the switch to for the high beam and to for the low beam. 3-5

20 INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch The starter motor cranks the engine when pushing the start switch. EC CAUTION: See starting instructions prior to starting the engine Engine stop switch 2. Lights switch 3. Start switch EAU00138 Engine stop switch The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system. Turn the switch to to start the engine. In case of emergency, turn the switch to to stop the engine. EAU00134 Lights switch Turning the light switch to, turns on the auxiliary light, meter lights and taillight. Turning the light switch to turns the headlight on also. 3-6

21 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Clutch lever 1. Adjusting dial 2. Arrow mark EAU00153 Clutch lever The clutch lever is located on the left handlebar. It is equipped with a clutch lever adjusting dial and a clutch switch, which is integrated into the ignition circuit cut-off system. (Refer to the engine starting procedures for a description of this system.) To disengage the clutch, pull the clutch lever toward the handlebar. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. To adjust the distance between the clutch lever and the handlebar grip, turn the clutch adjusting dial while pushing the lever forward. Make sure the setting on the clutch lever adjusting dial is aligned with the arrow mark. 1. Shift pedal EAU00157 Shift pedal This motorcycle is equipped with a constant-mesh 5-speed transmission. The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting. 3-7

22 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Front brake lever 1. Arrow mark 2. Adjusting dial EAU00161 Front brake lever The front brake lever is located on the right handlebar and is equipped with a brake lever adjusting dial. To activate the front brake, pull the lever toward the handlebar. To adjust the front brake lever position, turn the brake lever adjusting dial while pulling the lever forward. Make sure the setting on the brake lever adjusting dial is aligned with the arrow mark. 1. Rear brake pedal EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle. Press down on the brake pedal to apply the rear brake. 3-8

23 INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. EW Lock cover 2. Open WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle. 1. Filler tube 2. Fuel level EAU02935 Fuel tank cap To open Open the lock cover. Insert the key and turn it 1/4 turn clockwise. The lock will be released and the cap can be opened. To close Push the tank cap into position with the key inserted. To remove the key, turn it counterclockwise to the original position. Then, close the lock cover. EAU01183 Fuel Make sure there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown in the illustration. EW WARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube or it may overflow when the fuel heats up later and expands. 3-9

24 INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Always wipe off spilled fuel immediately with a dry and clean soft cloth. Fuel may deteriorate painted surfaces or plastic parts. ON: normal position RES: reserve position EAU00191 NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher. Fuel tank capacity: Total: 21 L Reserve: 4.5 L 1. Arrow mark positioned over ON EAU00207 Fuel cock The fuel cock supplies fuel from the tank to the carburetors while also filtering it. The fuel cock has three positions, which should be set as illustrated. ON With the fuel cock in this position, fuel flows to the carburetors when the engine is running. Set the fuel cock to this position when starting the engine and for riding. 1. Arrow mark positioned over RES RES This stands for reserve. If you are running out of fuel while riding with the fuel cock in the ON position, quickly turn the lever to this position. Otherwise the engine may die and will have to be primed (see PRI below). After turning the lever to RES, fill the tank at the first opportunity and be sure to set the fuel cock back to ON!

25 INSTRUMENT AND CONTROL FUNCTIONS PRI: priming position 3 1. Arrow mark positioned over PRI PRI This stands for prime. If the engine has been allowed to run out of fuel, turn the lever to the PRI position to send fuel directly to the carburetors. This will make starting easier. However, be sure to turn the lever to the ON position (or RES if you have not refuelled yet) after the engine has started. 1. Starter (choke) 1. Open EAU02976 Starter (choke) Starting a cold engine requires a richer air-fuel mixture. A separate starter circuit supplies this mixture. Move in direction a to turn on the starter (choke). Move in direction b to turn off the starter (choke). EAU01721 Seat To remove Insert the key in the helmet holder lock and turn it as shown. 3-11

26 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Projection 2. Seat holder To install Insert the projection on the front of the seat into the holder, then push down the seat. NOTE: Make sure that the seat is securely fitted. 1. Open 1. U-LOCK 2. Strap ( 2) EAU00260 Helmet holder To open the helmet holder, insert the key in the lock and turn it as shown. To lock the helmet holder, replace the holder in its original position. EW WARNING Never ride with a helmet in the helmet holder. The helmet may hit objects, causing loss of control and possibly an accident. EAU01688 Storage compartment This compartment is designed to store a genuine Yamaha U-LOCK. (Other locks may not fit.) Be sure the lock is fastened securely with the straps when storing it in the compartment. To prevent losing the straps, be sure to secure them even when a U-LOCK is not being stored in the compartment. When storing this Owner s manual or other documents in the compartment, be sure to put them in a vinyl bag so they do not get wet. When washing the motorcycle, be careful not to flood this compartment with water. 3-12

27 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Spring preload adjusting bolt 1. Setting 2. Front fork cap bolt EAU00285 Front fork adjustment This front fork is equipped with spring preload adjusting bolts. EW WARNING Each fork leg must be set to the same pressure. Uneven setting can cause poor handling and loss of stability. Adjust spring preload as follows. Turn the adjusting bolts in direction a to increase spring preload and in direction b to decrease spring preload. EC CAUTION: The grooves are provided to show the adjustment level. Always keep the adjustment level equal on both fork legs. CI-18E Adjusting position Hard Standard Soft Upper adjusting ring 2. Lower adjusting ring EAU01783 Rear shock absorber adjustment The shock absorbers are equipped with spring preload adjusting rings. To increase spring preload, turn the adjusting rings as shown in illustration a. 3-13

28 INSTRUMENT AND CONTROL FUNCTIONS 1. Upper adjusting ring 2. Lower adjusting ring To decrease spring preload, turn the adjusting rings as shown in illustration b. EW WARNING Always adjust each shock absorber to the same setting. Uneven adjustment can cause poor handling and loss of stability. Adjusting position HARD STD/SOFT EAU00316 WARNING These shock absorbers contain highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorbers. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. Do not tamper with or attempt to open the cylinder assemblies. Do not subject the shock absorbers to an open flame or other high heat source. This may cause the unit to explode due to excessive gas pressure. Do not deform or damage the cylinders in any way. Cylinder damage will result in poor damping performance. Take your shock absorbers to a Yamaha dealer for any service

29 INSTRUMENT AND CONTROL FUNCTIONS 3 1. Luggage strap holder ( 4) EAU00324 Luggage strap holders There are four luggage strap holders below the passenger seat, two of which can be turned outward for easier access. EAU00330 Sidestand This model is equipped with an ignition circuit cut-off system. The motorcycle must not be ridden when the sidestand is down. The sidestand is located on the left side of the frame. (Refer to page 5-1 for an explanation of this system.) EW WARNING This motorcycle must not be operated with the sidestand in the down position. If the stand is not properly retracted, it could contact the ground and distract the operator, resulting in a possible loss of control. Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand. Please check carefully the operating instructions listed below and if there is any indication of a malfunction, return the motorcycle to a Yamaha dealer immediately for repair. EAU00332 Sidestand/clutch switch operation check Check the operation of the sidestand switch and clutch switch against the information below. EW WARNING Be sure to use the centerstand during this inspection. If improper operation is noted, consult a Yamaha dealer. CD-08E TURN MAIN SWITCH TO ON AND ENGINE STOP SWITCH TO. TRANSMISSION IS IN GEAR AND SIDESTAND IS UP. PULL IN CLUTCH LEVER AND PUSH START SWITCH. ENGINE WILL START. 3-15

30 INSTRUMENT AND CONTROL FUNCTIONS CD-08E CLUTCH SWITCH IS OK. SIDESTAND IS DOWN. ENGINE WILL STALL. SIDESTAND SWITCH IS OK

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32 PRE-OPERATION CHECKS Pre-operation check list

33 4-PRE-OPERATION CHECKS EAU01114 Owners are personally responsible for their vehicle s condition. Your motorcycle s vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual inspection, you check the following points before each ride. PRE-OPERATION CHECK LIST EAU ITEM CHECKS PAGE Front brake Check operation, fluid level and vehicle for fluid leakage ~ 6-19 Rear brake Fill with DOT 4 brake fluid if necessary. Clutch Throttle grip and housing Engine oil Drive chain Wheels and tires Control and meter cables Brake and shift pedal shafts Brake and clutch lever pivots Center and sidestand pivot Check operation, fluid level and vehicle for fluid leakage. Fill with DOT 4 brake fluid if necessary. Check for smooth operation. Lubricate if necessary. Check oil level. Fill with oil if necessary. Check chain slack and condition. Adjust if necessary. Check tire pressure, wear and damage. Replace if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary. Check for smooth operation. Lubricate if necessary , ~ ~ ~ ~

34 PRE-OPERATION CHECKS Chassis fasteners Fuel Lights, signals and switches ITEM CHECKS PAGE Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check fuel level. Fill with fuel if necessary. 3-9 ~ 3-10 Check for proper operation ~ 6-27 NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accomplished in a very short time; and the added safety it assures is more than worth the time involved. 4 WARNING If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating the motorcycle. 4-2

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36 OPERATION AND IMPORTANT RIDING POINTS Starting the engine Starting a warm engine Shifting Recommended shift points (for Switzerland only) Tips for reducing fuel consumption Engine break-in Parking

37 5-OPERATION AND IMPORTANT RIDING POINTS EAU WARNING EAU00373 Before riding this motorcycle, become thoroughly familiar with all operating controls and their functions. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your motorcycle in an area with adequate ventilation. Before starting out, always be sure the sidestand is up. Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner. Starting the engine EAU00381 NOTE: This motorcycle is equipped with an ignition circuit cut-off system. The engine can be started only under one of the following conditions: The transmission is in neutral. The sidestand is up, the transmission is in gear and the clutch is disengaged. The motorcycle must not be ridden when the sidestand is down. EW WARNING Before going through the following steps, check the function of the sidestand switch and clutch switch. (Refer to page 3-15.) 5-1

38 OPERATION AND IMPORTANT RIDING POINTS CF-33E TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO. IF TRANSMISSION IS IN NEUTRAL AND SIDESTAND IS DOWN, IF TRANSMISSION IS IN GEAR AND SIDESTAND IS UP, PUSH THE START SWITCH. ENGINE WILL START. PULL IN THE CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START. RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR. 5 MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN. 5-2

39 OPERATION AND IMPORTANT RIDING POINTS 5 1. Turn the fuel cock to ON. 2. Turn the main switch to ON and the engine stop switch to. 3. Shift transmission into neutral. NOTE: When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 4. Turn on the starter (choke) and completely close the throttle grip. 5. Start the engine by pushing the start switch. NOTE: If the engine fails to start, release the start switch, wait a few seconds, then try again. Each attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. EC CAUTION: The oil level indicator light should come on when the start switch is pushed and should go off when the start switch is released. If the indicator light flickers or remains on, immediately stop the engine and check the engine oil level and for oil leakage. If necessary, fill the engine with oil and check to see that the oil level indicator light goes off. If the light does not go off even with sufficient oil in the crankcase or the light does not come on when pushing the start switch, consult a Yamaha dealer. 6. After starting the engine, move the starter (choke) halfway back. NOTE: For maximum engine life, never accelerate hard with a cold engine! 7. After the engine is warm, turn off the starter (choke) completely. NOTE: The engine is warm when it responds normally to the throttle with the starter (choke) turned off. 5-3

40 OPERATION AND IMPORTANT RIDING POINTS EAU01258 Starting a warm engine The starter (choke) is not required when the engine is warm. EC CAUTION: See the Engine break-in section prior to operating the motorcycle for the first time. 1. Shift pedal N. Neutral EAU00423 Shifting The transmission lets you control the amount of power you have available at a given speed for starting, accelerating, climbing hills, etc. The use of the shift pedal is shown in the illustration. To shift into neutral, depress the shift pedal repeatedly until it reaches the end of its travel, then raise the pedal slightly. EC CAUTION: Do not coast for long periods with the engine off, and do not tow the motorcycle a long distance. Even with gears in neutral, the transmission is only properly lubricated when the engine is running. Inadequate lubrication may damage the transmission. Always use the clutch when changing gears. The engine, transmission, and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch

41 OPERATION AND IMPORTANT RIDING POINTS 5 EAU02941 Recommended shift points (for Switzerland only) The recommended shift points are shown in the table below. CF-25E NOTE: When shifting two gears down from 4th to 2nd, bring your motorcycle to a speed of 35 km/h. 1st 2nd 2nd 3rd 3rd 4th 4th 5th Acceleration shift point (km/h) EAU00424 Tips for reducing fuel consumption Your motorcycle s fuel consumption depends to a large extent on your riding style. The following tips can help reduce fuel consumption: Warm up the engine before riding. Turn off the starter (choke) as soon as possible. Shift up swiftly and avoid high engine speeds during acceleration. Do not double-clutch or rev the engine while shifting down and avoid high engine speeds with no load on the engine. Turn off the engine instead of letting it idle for an extended length of time, i.e. in traffic jams, at traffic lights or railroad crossings. EAU01128 Engine break-in There is never a more important period in the life of your motorcycle than the period between zero and 1,600 km. For this reason we ask that you carefully read the following material. Because the engine is brand new, you must not put an excessive load on it for the first 1,600 km. The various parts in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged full throttle operation, or any condition which might result in excessive heating of the engine, must be avoided. 5-5

42 0 ~ 1,000 km Avoid operation above 4,000 r/min. EAU01329* 1,000 ~ 1,600 km Avoid cruising speeds in excess of 5,000 r/min. EC000052* CAUTION: After 1,000 km of operation, be sure to replace the engine oil and oil filter element. 1,600 km and beyond Proceed with normal riding. EC000053* CAUTION: Never let the engine speed enter the red zone. If any engine trouble should occur during the break-in period, consult a Yamaha dealer immediately. OPERATION AND IMPORTANT RIDING POINTS EAU00460 Parking When parking the motorcycle, stop the engine and remove the ignition key. EW WARNING The exhaust system is hot. Park the motorcycle in a place where pedestrians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground; the motorcycle may overturn

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44 PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit Periodic maintenance and lubrication Panel removal and installation Panel A Spark plugs Engine oil Air filter Carburetor adjustment Idle speed adjustment Throttle cable free play inspection Valve clearance adjustment Tires Wheels Rear brake pedal height adjustment Brake light switch adjustment Checking the front and rear brake pads Inspecting the brake fluid level Brake fluid replacement Drive chain slack check Drive chain slack adjustment Drive chain lubrication Cable inspection and lubrication Throttle cable and grip lubrication Brake and shift pedal lubrication Brake and clutch lever lubrication Center and sidestand lubrication Front fork inspection Steering inspection Wheel bearings Battery Fuse replacement Headlight bulb replacement Tail/brake light bulb replacement Turn signal light bulb replacement Front wheel removal Front wheel installation Rear wheel removal Rear wheel installation Troubleshooting Troubleshooting chart

45 6-PERIODIC MAINTENANCE AND MINOR REPAIR EAU EAU00464 Periodic inspection, adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible. Safety is an obligation of the motorcycle owner. The maintenance and lubrication schedule chart should be considered strictly as a guide to general maintenance and lubrication intervals. YOU MUST TAKE INTO CONSIDERATION THAT WEATHER, TERRAIN, GEOGRAPHICAL LOCA- TIONS, AND A VARIETY OF INDIVID- UAL USES ALL TEND TO DEMAND THAT EACH OWNER ALTER THIS TIME SCHEDULE TO SHORTER IN- TERVALS TO MATCH THE ENVI- RONMENT. The most important points of motorcycle inspection, adjustment, and lubrication are explained in the following pages. EW WARNING If you are not familiar with motorcycle service, this work should be done by a Yamaha dealer. 1. Tool kit EAU00469 Tool kit The service information included in this manual is intended to provide you, the owner, with the necessary information for completing some of your own preventive maintenance and minor repairs. The tools provided in the owner s tool kit are to assist you in the performance of periodic maintenance. However, some other tools such as a torque wrench are also necessary to perform the maintenance correctly. NOTE: If you do not have necessary tools required during a service operation, take your motorcycle to a Yamaha dealer for service. EW WARNING Modifications to this motorcycle not approved by Yamaha may cause loss of performance, and render it unsafe for use. Consult a Yamaha dealer before attempting any changes. 6-1

46 PERIODIC MAINTENANCE AND MINOR REPAIR CP-01E PERIODIC MAINTENANCE AND LUBRICATION NO. ITEM CHECKS AND MAINTENANCE JOBS 1 * Fuel line Check fuel hoses and vacuum hose for cracks or damage. Replace if necessary. 2 * Fuel filter Check condition. Replace if necessary. Check condition. 3 Spark plugs Clean, regap or replace if necessary. 4 * Valves Check valve clearance. Adjust if necessary. INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) EVERY EAU ,000 km or 12 months (whichever comes first) Every 24,000 km or 24 months (whichever comes first) 5 Air filter Clean or replace if necessary. 6 * Clutch Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 6-4.) Correct accordingly. 7 * Front brake (See NOTE on page 6-4.) Correct accordingly. Check operation, fluid level and vehicle for fluid leakage. Replace brake pads if necessary. 8 * Rear brake (See NOTE on page 6-4.) Correct accordingly. Check operation, fluid level and vehicle for fluid leakage. Replace brake pads if necessary. 9 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary

47 PERIODIC MAINTENANCE AND MINOR REPAIR 6 NO. ITEM CHECKS AND MAINTENANCE JOBS Check tread depth and for damage. 10 * Tires Replace if necessary. Check air pressure. Correct if necessary. 11 * Wheel bearings Check bearing for looseness or damage. Replace if necessary. Check swingarm pivoting point for play. 12 * Swingarm Correct if necessary. Lubricate with molybdenum disulfide grease every 24,000 km or 24 months (whichever comes first). 13 Drive chain Check chain slack. Adjust if necessary. Make sure that the rear wheel is properly aligned. Clean and lubricate. Check bearing play and steering for roughness. 14 * Steering bearings Correct accordingly. Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). 15 * Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary. Check operation. 16 Sidestand/centerstand Lubricate and repair if necessary. 17 * Sidestand switch Check operation. Replace if necessary. 18 * Front fork Check operation and for oil leakage. Correct accordingly. 19 * Rear shock absorber assemblies Check operation and shock absorbers for oil leakage. Replace shock absorber assembly if necessary. 6-3 INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) Every 1,000 km and after washing the motorcycle or riding in the rain EVERY 12,000 km or 12 months (whichever comes first)

48 PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM CHECKS AND MAINTENANCE JOBS 20 * Carburetors Check engine idling speed, synchronization and starter operation. Adjust if necessary. * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) EVERY 12,000 km or 12 months (whichever comes first) 21 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.) 22 Engine oil filter element Replace. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake and clutch systems After disassembling the master cylinder, caliper or clutch release cylinder, always replace the brake fluid. Check the brake fluid level of the master cylinder and clutch release cylinder regularly and fill as required. Replace the oil seals on the inner parts of the master cylinder, caliper and clutch release cylinder every two years. Replace the brake and clutch hoses every four years or if cracked or damaged. EAU

49 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1. Panel A 1. Screw ( 2) 2. Pull out EAU01777 Panel removal and installation The panel illustrated needs to be removed to perform some of the maintenance described in this chapter. Refer to this section each time the panel has to be removed or installed. EAU01551 Panel A To remove Remove the seat and panel screws. Then pull the panel outward as shown. 1. Projection 2. Grommet To install Insert the projection into the grommet and tighten the panel screws. 6-5

50 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Spark plug cap 1. Spark plug wrench Spark plugs Removal 1. Remove the spark plug caps. EAU Use the spark plug wrench in the tool kit to remove the spark plugs as shown. Inspection The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate the condition of the engine. Normally, all spark plugs from the same engine should have the same color on the white insulator around the center electrode. The ideal color at this point is a medium-to-light tan color for a motorcycle that is being ridden normally. If one spark plug shows a distinctly different color, there could be something wrong with the engine. Do not attempt to diagnose such problems yourself. Instead, take the motorcycle to a Yamaha dealer. You should periodically remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with the specified plug. Specified spark plug: DPR8EA-9 (NGK) or X24EPR-U9 (DENSO) 6 6-6

51 PERIODIC MAINTENANCE AND MINOR REPAIR 6 a. Spark plug gap Installation 1. Measure the electrode gap with a wire thickness gauge and, if necessary, adjust the gap to specification. NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the spark plug tightened to the specified torque as soon as possible. Tightening torque: Spark plug: 17.5 Nm (1.75 m kg) 4. Install the spark plug caps. EAU01784* Engine oil Oil level inspection 1. Place the motorcycle on the centerstand. Warm up the engine for several minutes. NOTE: Be sure the motorcycle is positioned straight up when checking the oil level. A slight tilt toward the side can result in false readings. Spark plug gap: 0.8 ~ 0.9 mm 2. Clean the gasket surface. Wipe off any grime from the threads. 3. Install the spark plug and tighten it to the specified torque. 6-7

52 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Oil level window 2. Maximum level mark 3. Minimum level mark 2. With the engine stopped, check the oil level through the level window located at the lower part of the right side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. 3. The oil level should be between the maximum and minimum level marks. If the level is low, add sufficient oil to raise it to the specified level. 1. Engine oil drain bolt 1. Oil filter drain screw 2. Oil filter cover bolt Engine oil and oil filter element replacement 1. Warm up the engine for several minutes. 2. Stop the engine. Place an oil pan under the engine and remove the oil filler cap. 3. Remove the drain bolt and drain the oil. 4. Remove the oil filter drain screw, filter cover bolt, filter cover, oil filter element and O-ring. 5. Reinstall the drain bolt and tighten it to the specified torque. Tightening torque: Drain bolt: 43 Nm (4.3 m kg) 6 6-8

53 PERIODIC MAINTENANCE AND MINOR REPAIR 9. Fill engine with oil. Install the oil filler cap and tighten Oil filter element 2. O-ring ( 2) 6. Install the new oil filter element and O-ring. 1. Projection 2. Slot 7. Align the projection on the filter cover with the slot in housing and install the filter cover. 8. Tighten the oil filter bolt and oil filter drain screw to the specified torque. Tightening torque: Oil filter bolt: 15 Nm (1.5 m kg) Oil filter drain screw: 7 Nm (0.7 m kg) EC CAUTION: Do not put in any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage. Be sure no foreign material enters the crankcase. Recommended oil: See page 8-1. Oil quantity: Total amount: 4.2 L Periodic oil change: 3.0 L With oil filter replacement: 3.35 L NOTE: Make sure the O-rings are seated properly. 6-9

54 PERIODIC MAINTENANCE AND MINOR REPAIR 10. Start the engine and warm it up for several minutes. While warming up, check for oil leakage. If oil leakage is found, stop the engine immediately and check for the cause. NOTE: After the engine is started, the oil level indicator light should go off if oil is filled to the specified level. EC CAUTION: If the indicator light flickers or remains on, immediately stop the engine and consult with a Yamaha dealer. 1. Air filter case cover 2. Screw ( 4) EAU01755 Air filter The air filter should be cleaned at the specified intervals. It should be cleaned more frequently if you are riding in unusually wet or dusty areas. 1. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 2. Remove panel A. (See page 6-5 for panel removal and installation procedures.) 3. Remove the air filter case cover by lifting up the wires as shown and removing the screws. 1. Air filter 4. Pull out the air filter

55 PERIODIC MAINTENANCE AND MINOR REPAIR 6 5. Tap the air filter lightly to remove most of the dust and dirt and blow out the remaining dirt with compressed air as shown. If the air filter is damaged, replace it. 6. Reassemble by reversing the removal procedure. EC CAUTION: Make sure the air filter is properly seated in the air filter case. The engine should never be run without the air filter installed. Excessive piston and/or cylinder wear may result. EAU00630 Carburetor adjustment The carburetors are important parts of the engine and require very sophisticated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner as part of routine maintenance. EC CAUTION: The carburetors were set at the Yamaha factory after many tests. If they are changed, poor engine performance and damage may result. EAU00632 Idle speed adjustment 1. Start the engine and warm it up for a few minutes at approximately 1,000 to 2,000 r/min. Occasionally rev the engine to 4,000 to 5,000 r/min. The engine is warm when it quickly responds to the throttle. 6-11

56 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Throttle stop screw 2. Set the idle to the specified engine speed by adjusting the throttle stop screw. Turn the screw in direction a to increase engine speed and in direction b to decrease engine speed. NOTE: If the specified idle speed cannot be obtained by performing the above adjustment, consult a Yamaha dealer. Standard idle speed: 1,000 ~ 1,100 r/min a. Free play EAU00635 Throttle cable free play inspection There should be a free play of 3 ~ 5 mm at the throttle grip. If the free play is incorrect, ask a Yamaha dealer to make this adjustment. EAU00637 Valve clearance adjustment The correct valve clearance changes with use, resulting in improper fuel/air supply or engine noise. To prevent this, the valve clearance must be adjusted regularly. This adjustment however, should be left to a professional Yamaha service technician

57 PERIODIC MAINTENANCE AND MINOR REPAIR 6 EAU00658 Tires To ensure maximum performance, long service and safe operation, note the following: Tire air pressure Always check and adjust the tire pressure before operating the motorcycle. EW WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature. Tire inflation pressure must be adjusted according to total weight of cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model), and vehicle speed. CE-33E Maximum load* 207 kg Cold tire pressure Front Rear Up to 90 kg load* 90 kg Maximum load* High speed riding 250 kpa (2.50 kg/cm 2, 2.50 bar) 250 kpa (2.50 kg/cm 2, 2.50 bar) 250 kpa (2.50 kg/cm 2, 2.50 bar) 250 kpa (2.50 kg/cm 2, 2.50 bar) 290 kpa (2.90 kg/cm 2, 2.90 bar) 290 kpa (2.90 kg/cm 2, 2.90 bar) * Load is the total weight of cargo, rider, passenger and accessories. EW WARNING Proper loading of your motorcycle is important for several characteristics of your motorcycle, such as handling, braking, performance and safety. Do not carry loosely packed items that can shift. Securely pack your heaviest items close to the center of the motorcycle, and distribute the weight evenly from side to side. Properly adjust the suspension for your load, and check the condition and pressure of your tires. NEVER OVERLOAD YOUR MOTOR- CYCLE. Make sure the total weight of the cargo, rider, passenger, and accessories (fairing, saddlebags, etc. if approved for this model) does not exceed the maximum load of the motorcycle. Operation of an overloaded motorcycle could cause tire damage, an accident, or even injury. 6-13

58 PERIODIC MAINTENANCE AND MINOR REPAIR EW Side wall a. Tread depth Tire inspection Always check the tires before operating the motorcycle. If center tread depth reaches the limit as shown, if the tire has a nail or glass fragments in it, or if the side wall is cracked, contact a Yamaha dealer immediately and have the tire replaced. WARNING Operating the motorcycle with excessively worn tires decrease riding stability and can lead to loss of control. Have excessively worn tires replaced by a Yamaha dealer immediately. Brakes, tires, and related wheel parts replacement should be left to a Yamaha Service Technician. CE-26E Minimum tire tread depth (front and rear) 1.6 mm NOTE: These limits may be different by regulation from country to country. If so, conform to the limits specified by the regulations of your own country. 1. Tire valve 2. Valve core 3. Valve cap with seal Tire information This motorcycle is equipped with tubeless tires, tire valves and cast wheels

59 PERIODIC MAINTENANCE AND MINOR REPAIR 6 WARNING EW After extensive tests, the tires mentioned below have been approved by Yamaha Motor Co., Ltd. for this model. No guarantee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle. The front and rear tires should be of the same manufacture and design. The use of tire valves and valve cores other than listed below could cause tire deflation during extreme high speed riding. Always use genuine parts or their equivalent for replacement. Be sure to install the valve caps securely, as these are important to prevent air pressure leakage during extreme high speed riding. CE-10E FRONT Manufacturer Size Type Dunlop 120/70ZR17 (58W) D207F Bridgestone 120/70ZR17 (58W) BT57F Michelin 120/70ZR17 (58W) MACADAM90X REAR Manufacturer Size Type Dunlop 180/55ZR17 (73W) D207 Bridgestone 180/55ZR17 (73W) BT57R Michelin 180/55ZR17 (73W) MACADAM90X CE-12E Type Tire valve TR412 Valve core #9000A (original) EAU00684 WARNING This motorcycle is fitted with super high-speed running tires. The following points must be observed in order for you to make fully effective use of these tires. Never fail to use the specified tires in tire replacement. Other tires may have a danger of bursting at super high-speeds. New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. Before any high-speed runs, the tires should be warmed-up sufficiently. Always inflate to the correct tire pressure according to the operating conditions. 6-15

60 PERIODIC MAINTENANCE AND MINOR REPAIR EAU00687 Wheels To ensure maximum performance, long service, and safe operation, note the following: Always inspect the wheels before a ride. Check for cracks, bends, or warpage of the wheels. If any abnormal condition exists in a wheel, consult a Yamaha dealer. Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replaced. Tires and wheels should be balanced whenever either one is changed or replaced. Failure to have a wheel balanced can result in poor performance, adverse handling characteristics, and shortened tire life. Ride at moderate speeds after changing a tire since the tire surface must first be broken in for it to develop its optimal characteristics. a. Brake pedal height EAU00712 Rear brake pedal height adjustment The top of the brake pedal should be positioned 40 mm below the top of the footrest. If not, ask a Yamaha dealer to adjust it. EW WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. This air must be removed by bleeding the brake system before the motorcycle is operated. Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident. Have a Yamaha dealer inspect and bleed the system if necessary

61 PERIODIC MAINTENANCE AND MINOR REPAIR 3. Turn the adjusting nut in direction a to make the brake light come on earlier. Turn the adjusting nut in direction b to make the brake light come on later. Front Rear 6 1. Brake light switch 2. Adjusting nut EAU01756 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect. Adjust the brake light switch as follows. 1. Remove panel A. (See page 6-5 for panel removal and installation procedures.) 2. Hold the switch body so it does not rotate while turning the adjusting nut. 1. Wear indicator ( 2) EAU00715 Checking the front and rear brake pads A wear indicator is provided on each brake. This indicator allows checking of brake pad wear without disassembling the brake. Apply the brake and inspect the wear indicator. If the indicator is ALMOST in contact with the disc plate, ask a Yamaha dealer to replace the pads. 6-17